Building panel construction and panel assemblies utilizing same

ABSTRACT

A building panel having opposite sides and parallel beveled edges defined respectively by facing sheets and by the parallel sides of the first and last trapezoidal corrugations of a longitudinally corrugated sheet sandwiched between the facing sheets, the longitudinally extending trapezoidal spaces between the corrugated sheet and the facing sheets being filled with urethane or like insulating foam which bonds the facing and corrugated sheets together and forms a strong monolithic section. The facing sheets and corrugations are preferably made of cardboard, and the facing sheets desirably have colored, patterned or textured surfaces. The panel herein is further characterized in that a reinforcing, weatherproofing, and protective skin of translucent or transparent plastic is applied over the sides and edges of the panel through which the colored, patterned, or textured surfaces of the facing sheets are visible. 
     The parallel beveled edges of the panels permit such panels to be assembled in edge-to-edge sealed relation over a foundation wall, or in partially overlapped and sealed relation on the rafters of a sloping roof, or in side-by-side relation with resilient strips therebetween on a flat or sloping roof. When used as horizontal siding in home construction, the edges of the panels may be placed in abutting engagement with such edges sloping downwardly away from the structure so that the joints are self-draining. A suitable caulking material may also be placed between the joints to provide a better seal between panels if desired. Alternately, the panel edges may be provided with extruded plastic or like strips for nailing directly to the wall studs and for interlocking the edges of successive panels in partially offset relation to resemble conventional siding construction. When used as vertical or diagonal siding in home construction, caulking may also be provided at the joints, or plastic coated and foam filled cardboard battens may be provided and sealed between successive panels or sealing strips may bridge the joints between adjacent panels.

This is a continuation of application Ser. No. 938,383, filed Aug. 31,1978.

BACKGROUND OF THE INVENTION

In the packaging field it is known to partly or wholly fill spaces incorrugated paperboard with sulphur foam (Jacquelin U.S. Pat. No.3,787,276), with urethane foam (Rodgers, Jr. U.S. Pat. No. 2,973,295),or with injection molded thermoplastic material such as polyethylene,polypropylene or styrene (Santangelo U.S. Pat. No. 3,364,638). In caseswhere water seepage resistance is necessary corrugated paperboard panelsmay be rendered moisture impervious by filling the spaces with colloidalclay such as bentonite (Clem U.S. Pat. No. 3,186,896).

It has also been proposed to use corrugated paperboard panels filled aswith asbestos fibers and expanded perlite particles as building panelsin much the same manner as plywood sheets are currently used (WandelU.S. Pat. No. 3,449,157). Another known form of laminated building sheetor panel comprises a corrugated metal spacing member with holes throughthe sidewalls of the corrugations sandwiched between metal facing sheetswith the spaces between the facing sheets and corrugated sheet beingfilled with cellular asbestos having the cells thereof disposedtransversely to the corrugations and keyed in the holes in the sidewallsof the corrugations (Coffman U.S. Pat. No. 2,234,517).

SUMMARY OF THE INVENTION

In contradistinction to known laminated sheets or panels, the panelconstituting the present invention is of a plank-like form havingopposite sides defined by facing sheets and parallel beveled edgesdefined by the sides of the first and last corrugations of atrapezoidally corrugated sheet sandwiched between the facing sheets,with the trapezoidal spaces between the facing sheets and the corrugatedsheet being filled with low density closed cell urethane or the likeinsulating foam which is foamed in place. The parallel beveled edges ofthe panels facilitate use of the panels in making either a butt orlapped joint between adjacent panels in a manner to be subsequentlydescribed. Preferably, the outer facing sheets and corrugated sheet aremade of a suitable cardboard-like material because of its relatively lowcost and ease of forming. For exterior use on a building construction,the opposite sides and edges of the panels may be colored, patterned ortextured, and a weatherproofing, reinforcing, and protective skin may beplaced thereover thereby resulting in a lightweight, strong,dimensionally stable, and thermal and sound insulating panel adapted tobe installed directly over the wall studs of a new building withoutrequiring sheathing or without requiring insulation between the studs.Also, such panels may be placed directly over existing wall and roofstructures for use in insulating existing structures less expensivelyand more effectively than other known methods presently being used.Presently there is no effective and economical way to fill the sidewallsof an existing structure with insulation. The panels of the presentinvention not only insulate more effectively and economically, but alsoprovide an attractive long life siding. The weatherproof coating andurethane also permit such panels to extend below ground level foreffective insulation of both the foundation as well as the area wherethe foundation structure meets the floor joists, and is particularlyapplicable to the retrofitting of old houses and other existingstructures. Insulating such area between the foundation and floor joistsis especially important for energy conservation, and yet until now therehas been no known way effectively and economically to provide suchinsulation.

One or more of such panels may also be adhesively bonded together beforethe outer protective skin is applied over the sides and outermost edgesof the joined panels to provide a single multiple width panel of anydesired width.

For interior use, the panel herein without the weatherproofing skin maybe installed on the inside of the wall studs of a new building or overthe existing wall of an old structure to provide increased insulation.The visible exterior surfaces of the panels used for interior use mayalso be colored, patterned or textured as in the case of the panels forexterior use, and such interior panels may also be covered withwallpaper or paneling if desired.

The plank-like panels herein may be face nailed in place, or oppositelydisposed longitudinally extending strips may be applied along the edgesthereof for interlocking the edges of successive panels in partiallyoffset relation and for facilitating the nailing of successive upperedges of the panels directly to the wall studs of a building wall. Forvertical or diagonal application of the panels herein over the wallstuds or existing wall panels, a suitable caulking material may be usedbetween the joints, or rigid insulating foam filled cardboard battensmay be bonded and sealed between the beveled edges of successive panelsor the edges of successive panels may be provided with interlockingstrips to retain the panels in coplanar relation with sealing stripsbridging the joints between the panels.

While the use of cardboard sheets for making the panels is preferred, itwill be apparent that other materials could be used if desired. Forexample, the panels could be made out of a one-piece extruded aluminumshape or extruded plastic and filled with urethane.

To the accomplishment of the foregoing and related ends, the invention,then, comprises the features hereinafter fully described andparticularly pointed out in the claims, the following description andthe annexed drawings setting forth in detail certain illustrativeembodiments of the invention, these being indicative, however, of butseveral of the various ways in which the principles of the invention maybe employed.

BRIEF DESCRIPTION OF THE DRAWINGS

In the annexed drawings:

FIG. 1 is a perspective view of one form of panel constituting thepresent invention;

FIGS. 2A and 2B are perspective views of molds for manufacturing a panelsimilar to that of FIG. 1;

FIG. 3 is a fragmentary vertical cross-section view of a buildingconstruction showing the panels according to the present invention inassembled relation over the foundation and exterior walls of thebuilding construction;

FIG. 4 is a fragmentary cross-section view showing a kickout stripnailed to the studs for offsetting the juxtaposed edges of successivepanels to resemble a conventional siding construction;

FIGS. 5A, 5B, and 5C illustrate another form of panel installation inwhich each panel has oppositely disposed strips on its upper and loweredges for nailing of the upper edges of successive panels to the studsand for interlocking successive panels in offset relation to resemble aconventional siding construction;

FIG. 6 is a fragmentary cross-section view similar to FIG. 3 exceptshowing the panels according to the present invention assembled invertically extending side-by-side relation;

FIG. 7 is a cross-section view along line 7--7 of FIG. 6 but on anenlarged scale showing the edges of adjacent panels in abuttingengagement with caulking material therebetween;

FIG. 8 is a cross-section view similar to FIG. 7 but showing how theedges of successive panels may be interlocked together with the jointscovered and sealed by a joint strip of plastic or like material;

FIG. 9 illustrates another vertical (or diagonal) panel assembly similarto FIG. 6 with intervening battens between the spaced apart edges ofsuccessive panels;

FIG. 10 illustrates a panel assembly applied on the rafters of a slopingroof;

FIG. 11 illustrates an assembly of panels applied on a flat or slopingroof having compression joints between successive panels; and

FIG. 12 is a side elevation view showing two or more panels in abuttingengagement along adjacent edges, bonded together, and having a one-pieceouter layer of glass fiber reinforced plastic covering the sides of suchpanels and extending over the joints therebetween to provide a singlemultiple width panel.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The panel 1 illustrated in FIG. 1 comprises parallel cardboard facingsheets 2 and 3 with a trapeozoidally corrugated cardboard sheet 4sandwiched between the facing sheets 2 and 3 with the flat crests of thecorrugated sheet 4 contacting the respective facing sheets 2 and 3. Theparallel beveled edges 5 of the panel 1 are defined by the sides of thefirst and last corrugations. The longitudinally extending trapeozoidalspaces defined between the facing sheets 2 and 3 and the corrugatedsheet 4 are filled with a closed cell low density insulating foam 6,preferably urethane, which has a thermal conductivity (k-factor) fromabout 0.11 to 0.17 BTU/sq. ft./hr./°F./in., and has excellent adhesiveproperties. As the urethane rises and expands during foaming, it adheresto the surfaces of the facing and corrugated sheets 2, 3, and 4 whichdefine the trapeozoidal spaces thus serving to retain the entire systemtogether and form a very strong monolithic section providing the basicmodule on which color, print, or texture may be applied. Afterwards, theopposite sides 2 and 3 and edges 5 of the panel are covered by areinforcing, protective and weatherproofing skin 7 of glass fiberreinforced plastic or other similar and suitable material. The skin 7 ispreferably translucent or transparent so that the opposite sides 2 and 3and edges 5 of the panel, if colored, patterned, textured or otherwisefinished as aforesaid, will be visible through the skin 7 for appearancewhile protected by the skin 7 from weather or other damage.

In one example of a panel 1 according to the present invention, thepanel was made approximately 11/2" thick and the opposite sides 2 and 3approximately 12" wide, using cardboard for both the facing sheets 2 and3 and corrugated sheet 4 approximately 0.050" thick. The skin 7 waslikewise approximately 0.050" thick. The panel 1 according to theillustrative example has a density of about 2.3 lbs./cu. ft. In thisexample the pitch of the corrugations was approximately 3" and thecrests of the corrugations were about 3/4" wide.

As known, low density urethane foam is one of the most efficient thermalinsulations commercially available with initial thermal conductivity(k-factor) in the range of 0.11 to 0.14 BTU/in./sq. ft./°F./hr. for 2lb./cu. ft. foam. Of course, the lower the k-factor the more efficientthe insulation. The usual densities of spray foam are from 2 to 6lbs./cu. ft. depending on the strength and rigidity required. Proposedfederal regulations may require new buildings in northern states to havethermal resistances (R-factors) of 19 sq. ft./°F./hr./BTU.

If a panel according to FIG. 1 is desired in 2, 3, or 4 foot widths, theedges 5 of two, three, or four panels 1 without the skin 7 may beadhesively bonded together to form the desired width of panel and thenthe glass fiber reinforced skin 7 may be applied over the sides andoutermost edges of the multiple width panel, as illustratively shown inFIG. 12.

In another example of a panel 1 according to the present invention, thefacing sheets 2 and 3 and the corrugated sheet 4 were made of cardboardof 0.080" thickness with a fiber glass reinforced skin 0.025" thickness,the thickness of the panel 1 being 31/2" and the pitch of thecorrugations being 2" with flat crests of 3/4". It was found that suchpanel when supported by supports five feet apart crosswise of thecorrugations supported an 844 lb. load with a total initial deflectionof about 0.205 inch. The total cross section moment of inertia was about20 in.⁴ and the apparent composite modulus of elasticity was 0.924×10⁶psi. The total composite R-factor using urethane foam of 2.2 lb./cu. ft.density was R-24 and using urea foam at 2.2 lb./cu. ft. was R-19.

In the panel illustrated in FIG. 1, the facing sheets 2 and 3 andcorrugateed sheet 4 are shown as comprising a single sheet of cardboardwhich is scored and folded first to form one facing sheet 2, then thecorrugated sheet 4, and lastly the other facing sheet 3. Alternatively,the facing sheets 2 and 3 and corrugated sheet 4 are each made fromseparate sheets.

FIGS. 2A and 2B schematically illustrate how a panel 1 according to thepresent invention may be constructed using separate sheets for thefacing sheets 2 and 3 and corrugated sheet 4. In FIG. 2A the corrugatedsheet 4 is placed on a corrugated lower mold section 8 and measuredamounts of a suitable foam mixture of urethane or the like areintroduced into the upwardly facing open triangular sections.Immediately thereafter the facing sheet 2 is placed over the corrugatedsheet and restrained in place by the upper mold section 9 until foamingis complete and the plastic material has cured. The adhesive qualitiesof the urethane cause the facing sheet 2 and half foamed corrugatedsheet 4 to become a monolithic structure. The partially completed panelas formed in the mold 8-9 of FIG. 2A is then inverted and placed in thelower mold section 10 of FIG. 2B and the foam plastic mixture is placedinto the valleys of the corrugations and the other facing sheet 3 isplaced against the crests of the corrugations whereupon the foam plasticmay be cured with the upper mold section 11 of FIG. 2B clamped in placeto form a finished panel comprising the facing sheets 2 and 3 bonded tothe corrugated sheet 4 and the rigid foam which fills the longitudinallyextending trapeozoidal spaces defined between the facing sheets 2 and 3and the corrugated sheet 4. The panel 1 made according to FIGS. 2A and2B may then be covered by the glass fiber reinforced plastic skin 7 asdepicted in FIG. 1.

In FIG. 3 the panels 1 are assembled in horizontally extendingedge-to-edge relation over the foundation wall W of a building above andbelow grade to form a thermal insulating barrier for the foundation wallW. The parallel beveled edges 5 of adjacent panels are shown in fullcontacting abutting engagement with each other and sloping outwardly anddownwardly away from the foundation wall thus to aid in keeping waterand moisture from seeping between adjacent panels. The edges 5 of thepanels 1 are also preferably sealed by applying a suitable caulkingmaterial between the abutting edges 5 as the panels 1 are put in place.In addition, the rear sides of the panels 5 may be adhesively andsealingly secured to the outside of the foundation wall W, or suchpanels may be secured in place by nailing and the like.

In conventional home construction as shown in FIG. 3 the top of thefoundation wall W has secured thereon a plate 12 upon which the floorjoists 13 are supported. Across the ends of the joists 13 is a framingmember 14 which boxes in the floor structure to form a support for thesubfloor 15 and for the plate 16 for the wall studs 17. The inside wall18 of the structure shown in FIG. 3 may comprise the usual dry wall orplaster board nailed to the studs 17. In the building construction shownin FIG. 3, the panels 1 above grade are shown installed to resemblehorizontal siding with the parallel beveled edges of adjacent panels infull contacting abutting engagement with each other and slopingdownwardly and outwardly to prevent water from seeping in between thejoints and make the joint self-draining. The panels may be secured inplace as by face nailing, and a suitable caulking material may beapplied between the joints as required. The exterior panel sidingdesirably extends below ground level at least a foot or so toeffectively insulate the area where the foundation structure meets thefloor joists, and such siding may continue to the full depth of thefoundation as shown. The weatherproof coating and urethane protect suchpanels against deterioration for long life both above and below groundlevel, and such panels not only provide more effective and economicalinsulation for structures than other known methods, but also provide anattractive long life siding.

In FIG. 4, the panels are also shown installed to resemble horizontalsiding, similar to FIG. 3, but with the lower edges of the panels 1outwardly offset with respect to the upper edges of the panels 1 whichmay be nailed directly to the studs 17. The offsetting may be achievedas by kickout strips 19 of metal or plastic also nailed to the studs 17.Each panel 1 may have a sealant and adhesive 20 applied to its upper andlower edges to bond and seal the panel edges to the flanges 21 of thekickout strip 19. As shown, the beveled panel edges slope downwardly andoutwardly from the building structure to facilitate water runoff and aidin keeping water and moisture from seeping in between adjacent panels.

In the siding installation shown in FIGS. 5A, 5B and 5C the upper edge 5of each panel 1 has adhesively bonded thereto an extruded plastic strip23 or the like having a series of holes therein of which at least onehole registers with each stud 17 for nailing as shown in FIG. 5A, saidstrip 23 having a ridge 24 between its ends and a rearwardly extendingflange 25 at its outer end on which a suitable adhesive or caulking likematerial 26 is adapted to be applied. The lower edge 5 of each panel 1has an oppositely disposed extruded plastic strip 23 bonded thereto toprovide a downwardly extending ridge 24 between its ends and a forwardlydirected flange 25 arranged to cooperate with the flange 25 on the strip23 on the upper edge 5 of the panel 1, FIG. 5B showing the partiallyinterengaged flanges 25 and FIG. 5C showing the final interlockedposition of the lower edge 5 of one panel 1 with the upper edge 5 of theadjacent panel 1 with outer ridge 24 forming a fillet and the sealant 26being effective to seal the joint and to bond together the lower andupper edges 5 of adjacent panels 1.

FIGS. 6 and 7 illustrate an installation of such panels 1 in verticalside-by-side relation for use both as exterior siding insulation aboveground level and extending below ground level for insulating thefoundation as well. The edges of adjacent panels may be in closeabutting engagement as shown in FIG. 7, with caulking materialtherebetween to provide a waterproof joint, and secured in place as byface nailing. Alternatively, the edges of adjacent panels may beprovided with cooperating oppositely disposed strips 27 having ridges 28and hook-like flanges 29 which cooperate to retain the panels in flushrelationship as shown in FIG. 8. The vertical joints may also be sealedas by a batten or strip 30 made, for example, of plastic or a corrugatedboard core with fiber glass coating, and having a pressure sensitiveadhesive coating 31 and a flange 32 parallel to the beveled edges of thepanels and having a hook to engage between the end of the outer flange29 and the ridge 28 when the strip 30 is pushed into place to bridge andseal the joint. In view of the stiffness and dimensional stability ofthe panels 1 herein it is not necessary when installing the panelsvertically as shown in FIGS. 6 and 7 to attach the panels 1 to the studs17 whereby it suffices to bond the panels 1 to the foundation wall W,and to the bottom and top of the stud wall.

FIG. 9 is a fragmentary cross-section view of another installation ofthe panels 1 herein in vertical (or diagonal) position and employingdecorative battens 34 between the edges 5 of the panels 1 which, likethe panels 1, may comprise rigid foam filled cardboard having a plasticskin. As shown in FIG. 9 the panels 1 are spaced apart with the battens34 therebetween adhesively and sealingly bonded to the edges of thepanels 1. Such panels and battens may also be secured in place as byface nailing, with suitable caulking between joints to provide thedesired seal.

FIG. 10 shows the use of panels 1 according to the present invention ona sloping roof, the panels being secured together in overlappingrelation and being secured to the rafters as by adhesive or nailing.

FIG. 11 illustrates the application of the panels 1 herein to a flat (orsloping) roof with elastomeric compression joints 38 including forexample a foam rubber core 39 and flanges 40 which sealingly embraceopposite sides of the panels 1. The FIG. 11 construction may also beapplied on a sloped roof and in either case the panels 1 are preferablyof two, three, or four foot widths fabricated as previously mentioned byadhesively bonding together and abutting edges of the cardboard sides ofcorrugated sheets 4 followed by applying the glass fiber reinforcedplastic skin 7 around the sides 2 and 3 and edges 5 of the individualtwo, three or four foot wide panels 1.

Also as previously mentioned, the panels 1 herein without the outer skin7 may be installed interiorly in vertical or horizontal position to forman interior wall surface suitable for painting, wallpapering, orpaneling as in the case of the conventional dry wall construction 18 butproviding extra insulation together with the insulation of theexteriorly applied panels 1. In any case, by using the panels 1 hereinit is not necessary to have any insulation between the studs 17.

The panel 1 herein has an almost limitless potential of designs,patterns, colors and textures because the color, texture and/or designis applied to the cardboard surfaces of the facing sheets 2 and 3 of thebasic panel either before or after it is produced and filled with rigidinsulating foam 6. The color or design may be printed on the cardboardor applied to the cardboard surfaces with inexpensive materials overwhich the transparent or translucent plastic skin 7 is applied. Thetruss-like internal structure of the panel 1 herein together with theintegral foam support 6 produces a panel 1 with relatively greatstiffness which approximates the modulus of elasticity of many grades oflumber and which contributes greatly to the allowable span of the panel1 herein. In sections of greater depth or thickness this stiffnessfactor will be adequate for residential load bearing exterior andinterior walls. It is also preferred that panels 1 herein be made inrelatively long lengths which may readily be sawed to desired lengths toavoid end-to-end joints as in the installations depicted in FIGS. 3 to11.

Moreover, the panels may be used in new building construction either asexterior or interior finish sheeting or both in lieu of the usual sidingor sheeting, and such panels may also be placed directly over existingwall and roof structures to provide desired insulation much moreeffectively and less expensively than other known methods presently inuse.

While the use of cardboard to make the panels is preferred because ofits relatively low cost and ease of forming, the panels could also bemade from other materials, including a one-piece extruded aluminum shapeor extruded plastic panel filled with urethane and the like.

Although the invention has been shown and described with respect toseveral preferred embodiments, it is obvious that equivalent alterationsand modifications will occur to others skilled in the art upon thereading and understanding of this specification. The present inventionincludes all such equivalent alterations and modifications and islimited only by the scope of the claims.

The embodiments of the invention in which an exclusive property orprivilege is claimed are defined as follows:
 1. A building panelconstruction comprising a pair of facing sheets defining opposite sidesof the panel; a trapezoidally corrugated sheet sandwiched between saidfacing sheets, the corrugations of said corrugated sheet havingoppositely facing flat crests engaging said facing sheets, the first andlast corrugations of said corrugated sheet having flat sides definingopposite beveled parallel edges of said panel adapted for buttedengagement with the beveled edge of another panel; said edges of saidpanel having oppositely disposed longitudinally extending stripsattached thereon for interlocking engagement with strips on the edges ofadjacent panels; and rigid foam insulation filling the trapezoidalspaces defined between said facing sheets and corrugated sheet andbonded to the facing sheets and corrugated sheet.
 2. The panelconstruction of claim 1 wherein said strips are operative to interlockthe edges of adjacent panels in offset relation.
 3. The panelconstruction of claim 2 wherein said strips are perforated to facilitatenailing of the upper edges of horizontally extending panels to wallstuds adjacent the acute angle corners of such upper edges.
 4. The panelconstruction of claim 1 wherein said strips are operative to interlockadjacent panels in flush relationship.
 5. The panel construction ofclaim 4 wherein a sealing strip bridges the joint between the edges ofadjacent panels.
 6. In a building construction including exteriorvertical walls, the combination therewith of a plurality of buildingpanels overlying said vertical walls, each panel comprising a pair offacing sheets defining the opposite sides of the panel, a trapezoidallycorrugated sheet sandwiched between said facing sheets, the sides of thefirst and last corrugations being flat and defining parallel bevelededges of said panel adapted for butted engagement with the beveled edgeof another panel, and rigid foam insulation filling the trapezoidalspaces defined between said facing sheets and said corrugated sheet andbonded to said facing sheets and corrugated sheet, the exterior surfaceof said panel being weatherproof; said panels extending generallyhorizontally and being assembled with said edges of adjacent panels insealed abutting offset relation to resemble conventional sidingconstruction and to provide a weatherproof and insulating layer oversaid exterior vertical wall, said panels disposed in offset relationhaving longitudinally extending strips for interlocking said panels inpredetermined offset relation, and said strips adjacent the acute anglecorners of the upper edges of successive panels being nailed to saidexterior vertical walls.
 7. In a building construction includingexterior vertical walls, the combination therewith of a plurality ofbuilding panels overlying said vertical walls, each panel comprising apair of facing sheets defining the opposite sides of the panel, atrapezoidally corrugated sheet sandwiched between said facing sheets,the sides of the first and last corrugations being flat and definingparallel beveled edges of said panel adapted for butted engagement withthe beveled edge of another panel, and rigid foam insulation filling thetrapezoidal spaces defined between said facing sheets and saidcorrugated sheet and bonded to said facing sheets and corrugated sheet,the exterior surface of said panel being weatherproof; said panels beingassembled in vertical side-by-side relation with said edges of adjacentpanels in sealed butted relation to provide a weatherproof andinsulating layer over said exterior vertical wall, said panels havingelongated strips along the opposite edges thereof which interlock withthe strips of adjacent panels, and sealing strips bridging the jointsbetween adjacent panels to form a sealed wall construction overlyingsaid exterior vertical walls.
 8. In a building construction includingexterior vertical walls, the combination therewith of a plurality ofbuilding panels overlying said vertical walls, each panel comprising apair of facing sheets defining the opposite sides of the panel, atrapezoidally corrugated sheet sandwiched between said facing sheets,the sides of the first and last corrugations being flat and definingparallel beveled edges of said panel adapted for butted engagement withthe beveled edge of another panel, and rigid foam insulation filling thetrapezoidal spaces defined between said facing sheets and saidcorrugated sheet and bonded to said facing sheets and corrugated sheet,the exterior surface of said panel being weatherproof; said panels beingassembled with said edges of adjacent panels in spaced side-by-siderelation with rigid foam-filled battens sealingly bonded between thespaced apart edges of adjacent panels to provide a weatherproof andinsulating layer over said exterior vertical wall.
 9. In a buildingconstruction including exterior vertical walls and a roof structure, thecombination therewith of a plurality of building panels overlying saidroof structure; each panel comprising a pair of facing sheets definingthe opposite sides of the panel, a trapezoidally corrugated sheetsandwiched between said facing sheets, the sides of the first and lastcorrugations being flat and defining parallel beveled edges of saidpanel adapted for butted engagement with the beveled edge of anotherpanel, and rigid foam insulation filling the trapezoidal spaces betweensaid facing sheets and said corrugated sheet and bonded to said facingsheets and corrugated sheet, the exterior surface of said panel beingweatherproof; said panels being assembled with said edges of adjacentpanels in sealed relation to provide a weatherproof and insulating layerover said roof structure, and elastomeric compression joints between theedges of adjacent panels, said joints including a foam rubber core andflanges which sealingly embrace opposite sides of said panels.
 10. Abuilding panel construction comprising a pair of facing sheets definingopposite sides of the panel; a corrugated sheet sandwiched between saidfacing sheets, said panel having opposite beveled flat parallel edgesdefined by the first and last corrugations of said corrugated sheet,said parallel edges extending from one facing sheet to the other at theopposite ends thereof adapted for butted engagement with the bevelededge of another panel; and rigid foam insulation filling the spacesdefined between said facing sheets and corrugated sheet and bonded tothe facing sheets and corrugated sheet.
 11. The panel construction ofclaim 10 wherein said facing sheets and corrugated sheet are ofcardboard.
 12. The panel construction of claim 10 wherein thecorrugations of said corrugated sheet have oppositely facing flat crestsengaging said facing sheets.
 13. The panel construction of claim 10wherein said opposite sides and edges of said panel have a plasticprotective, weatherproofing, and reinforcing skin thereover.
 14. Thepanel construction of claim 13 wherein said plastic skin is translucentor transparent; and wherein the outer surfaces of said facing sheets arecolored, patterned, or textured.
 15. The panel construction of claim 13wherein said skin has glass fibers therein imparting additionalstiffness and strength to said panel.
 16. The panel construction ofclaim 10 wherein at least two of said panels have abutting edges bondedtogether, and a unitary plastic protective, weatherproofing andreinforcing skin extends over the sides of said bonded panels and theoutermost edges of the outermost bonded panels.
 17. The panelconstruction of claim 10 wherein said facing sheets and said corrugatedsheet comprise a single sheet of cardboard.
 18. In a buildingconstruction including a foundation wall, the combination therewith of aplurality of building panels as set forth in claim 10 in side-by-siderelation overlying said foundation wall; the exterior surface of saidpanels being weatherproof; said panels being assembled with said edgesof adjacent panels in sealed butted relation to provide a weatherproofand insulating layer over said foundation wall.
 19. The buildingconstruction of claim 18 wherein said panels extend generallyhorizontally with the edges of adjacent panels sloping downwardly andoutwardly away from said foundation wall.
 20. The building constructionof claim 18 wherein said panels extend generally vertically with theedges of said panels being sealed in flush edge-to-edge relation. 21.The building construction of claim 18 further comprising a plastic skinoverlying the opposite sides and edges of each of said panel.
 22. Thebuilding construction of claim 18 wherein at least two of said panelshave abutting edges bonded together, and a unitary plastic protective,weatherproofing and reinforcing skin extends over the sides of saidbonded panels and outermost edges of the outermost bonded panels. 23.The building construction of claim 18 further including exteriorvertical walls, the outermost surface of which comprises a plurality ofsaid building panels.
 24. The building construction of claim 23 whereinsaid exterior vertical walls include vertical exterior wall studs, saidbuilding panels overlying said wall studs and attached thereto.
 25. Thebuilding construction of claim 23 wherein said exterior vertical wallsinclude exterior siding, and said building panels overlie said exteriorsiding.
 26. The building construction of claim 18 further including aroof structure the outermost surface of which comprises a plurality ofsaid building panels.
 27. The building structure of claim 26 whereinsaid roof structure includes an existing exterior roofing, said buildingpanels overlying said existing roofing.
 28. In a building constructionincluding exterior vertical walls, the combination therewith of aplurality of building panels each as set forth in claim 10 overlyingsaid vertical walls; said panels being assembled with said edges ofadjacent panels in sealed butted relation to provide a weatherproof andinsulating layer over said exterior vertical wall.
 29. The buildingconstruction of claim 28 wherein said building panels extend generallyhorizontally, with the adjacent edges of said building panels being inabutting offset relation to resemble conventional siding construction.30. The building construction of claim 28 wherein said facing sheets andcorrugated sheets are made of cardboard.
 31. The building constructionof claim 30 wherein the opposite sides and edges of said panels have aplastic protective, weatherproofing, and reinforced skin thereover. 32.The building construction of claim 30 wherein at least two of saidpanels have abutting edges bonded together, and there is a unitaryplastic protective, weatherproofing and reinforcing skin over the sidesof said bonded panels and the outermost edges of the outermost bondedpanels.
 33. The building construction of claim 29 wherein said exteriorvertical walls include exterior siding, said panels overlying saidexterior siding.
 34. The building construction of claim 28 wherein saidexterior vertical walls include vertical external wall studs, saidpanels overlying said wall studs and attached thereto.
 35. In a buildingconstruction including exterior vertical walls, the combinationtherewith of a plurality of building panels each as set forth in claim10; said panels being assembled with said edges of adjacent panels inspaced side-by-side relation with rigid foam-filled battens sealinglybonded between the spaced apart edges of adjacent panels to provide aweatherproof and insulating layer over said exterior vertical walls. 36.In a building construction including exterior vertical walls and a roofstructure, the combination therewith of a plurality of building panelseach as set forth in claim 10 overlying said roof structure; said panelsbeing assembled with said edges of adjacent panels in sealed buttedrelation to provide a weatherproof and insulating layer over said roofstructure.
 37. The building construction of claim 36 wherein said roofstructure slopes, said panels being secured together in overlappingrelation over said sloping roof structure and secured thereto.
 38. In abuilding construction including interior vertical walls, the combinationtherewith of a plurality of building panels each as set forth in claim10 in side-by-side butted relation overlying said vertical walls, saidbeveled edges of said panels being butted with said panels in line todefine a layer of said panels overlying said vertical walls.
 39. Abuilding panel construction comprising a pair of facing sheets definingopposite sides of the panel; a corrugated sheet sandwiched between saidfacing sheets, said panel having opposite beveled flat parallel edgesextending from one facing sheet to the other at the opposite endsthereof adapted for butted engagement with the beveled edge of anotherpanel; said edges of said panel having oppositely disposedlongitudinally extending strips attached thereon for mechanicalinterlocking engagement with strips on the edges of adjacent panels; andrigid foam insulation filling the spaces defined between said facingsheets and corrugated sheet and bonded to the facing sheets andcorrugated sheet.
 40. In a building construction including a foundationwall, the combination therewith of a plurality of building panels inside-by-side relation overlying said foundation wall; each buildingpanel comprising a pair of facing sheets defining opposite sides of thepanel, a corrugated sheet sandwiched between said facing sheets, saidpanel having opposite beveled flat parallel edges extending from onefacing sheet to the other at the opposite ends thereof adapted forbutted engagement with the beveled edge of another panel, and rigid foaminsulation filling the spaces defined between said facing sheets andcorrugated sheet and bonded to the facing sheets and corrugated sheet;the exterior surface of said panels being weatherproof; said panelsbeing assembled with said edges of adjacent panels in sealed buttedrelation to provide a weatherproof and insulating layer over saidfoundation wall, and further including exterior vertical walls, theoutermost surface of which comprises a plurality of said buildingpanels, said building panels which comprise the outermost surface ofsaid exterior walls extending generally horizontally and being assembledwith said edges in sealed butting offset relation to resembleconventional siding construction, said panels disposed in offsetrelation having longitudinally extending strips for interlocking saidpanels in predetermined offset relation, and said strips adjacent theacute angle corners of the upper edges of successive panels being nailedto said exterior vertical walls.
 41. In a building constructionincluding exterior vertical walls, the combination therewith of aplurality of building panels overlying said vertical walls; eachbuilding panel including a pair of facing sheets defining opposite sidesof the panel, a corrugated sheet sandwiched between said facing sheets,said panel having opposite beveled flat parallel edges extending fromone facing sheet to the other at the opposite ends thereof adapted forbutted engagement with the beveled edge of another panel, and rigid foaminsulation filling the spaces defined between said facing sheets andcorrugated sheet and bonded to the facing sheets and corrugated sheet;said panels being assembled with said edges of adjacent panels in sealedbutted relation to provide a weatherproof and insulating layer over saidexterior vertical wall; said panels extending generally horizontally andbeing assembled with said edges of adjacent panels in sealed abuttingoffset relation to resemble conventional siding construction, saidpanels disposed in offset relation having longitudinally extendingstrips for interlocking said panels in predetermined offset relation,said strips adjacent the acute angle corners of the upper edges ofsuccessive panels being nailed to said exterior vertical walls.
 42. In abuilding construction including exterior vertical walls, the combinationtherewith of a plurality of building panels overlying said verticalwalls; each building panel including a pair of facing sheets definingopposite sides of the panel, a corrugated sheet sandwiched between saidfacing sheets, said panel having opposite beveled flat parallel edgesextending from one facing sheet to the other at the opposite endsthereof adapted for butted engagement with the beveled edge of anotherpanel, and rigid foam insulation filling the spaces defined between saidfacing sheets and corrugated sheet and bonded to the facing sheets andcorrugated sheet; said panels being assembled with said edges ofadjacent panels in sealed butted relation to provide a weatherproof andinsulating layer over said exterior vertical wall; said panels beingassembled in vertical side-by-side relation with said edges of adjacentpanels in sealed butted relation as aforesaid to provide a weatherproofand insulating layer over said exterior vertical walls, said panelshaving elongated strips along the opposite edges thereof which interlockwith the strips of adjacent panels, and sealing strips bridging thejoints between adjacent panels to form a sealed wall constructionoverlying said exterior vertical walls.
 43. In a building constructionincluding exterior vertical walls and a roof structure, the combinationtherewith of a plurality of building panels overlying said roofstructure; each building panel including a pair of facing sheetsdefining opposite sides of the panel, a corrugated sheet sandwichedbetween said facing sheets, said panel having opposite beveled flatparallel edges extending from one facing sheet to the other at theopposite ends thereof adapted for butted engagement with the bevelededge of another panel, and rigid foam insulation filling the spacesdefined between said facing sheets and corrugated sheet and bonded tothe facing sheets and corrugated sheet; said panels being assembled withsaid edges of adjacent panels in sealed butted relation to provide aweatherproof and insulating layer over said roof structure; andelastomeric compression joints between the edges of adjacent panels,said joints including a foam rubber core and flanges which sealinglyembrace opposite sides of said panels.